Spray applicator

ABSTRACT

A spray assembly for dispensing a mixture is provided. The spray assembly includes a connector configured for operable engagement with a first and a second source of component and a source of pressurized fluid, and a tip operably connected to the connector. The tip includes an opening and defines a mixing chamber between the connector and the opening of the tip, and an insert member configured to be received in the mixing chamber. The insert member includes a plurality of radially extending slots on at least one end of the insert. The plurality of radially extending slots is configured to mix the first and second components prior to the mixture exiting the opening in the tip.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of and priority to U.S. ProvisionalPatent Application No. 61/096,345, filed Sep. 12, 2008, the entiredisclosure of which is incorporated by reference herein.

BACKGROUND

1. Technical Field

The present disclosure relates to spray applicators and methods ofmixing two or more components. More particularly, the present disclosurerelates to a spray assembly for mixing and applying a bioadhesive.

2. Background of Related Art

Polymers and other synthetic materials are currently being developed foruse in internal and external wound closure. “Bioadhesives” are known inthe art, as are various methods for applying the bioadhesive.Bioadhesives offer many significant advantages over conventional woundclosure methods, i.e., using sutures, staples, clips or other suitablemechanical fasteners. Bioadhesives are faster and simpler to apply andhave a tendency to promote quicker wound healing with less scarring.

Most bioadhesives are composed of components that have a tendency toimmediately activate and in some instances, rapidly polymerize whencombined with one another. Because of this immediate activation and/orrapid polymerization of the bioadhesive, the components comprising thebioadhesive may not be combined until immediately prior to application.

The increased use of endoscopic surgery for even some of the mostcomplex procedures has presented a need for an applicator configured toapply a bioadhesive through an endoscopic port.

SUMMARY

Provided is a spray assembly for dispensing a mixture. The sprayassembly includes a connector configured for operable engagement with afirst and a second source of component and a source of pressurizedfluid, a tip operably connected to the connector, the tip including anopening and defining a mixing chamber between the distal end of theelongated member and the opening of the tip, and an insert memberconfigured to be received in the mixing chamber, the insert memberincluding a plurality of radially extending slots on at least one end ofthe insert, the plurality of radially extending slots being configuredto mix the first and second components prior to the combination exitingthe opening in the tip. The spray assembly may further include anelongated member extending between the connector and the tip, theelongated member having at least a first lumen configured for fluidcommunication with the first source of component, a second lumenconfigured for fluid communication with the second source of component,and a third lumen configured for fluid communication with the source ofpressurized fluid. The spray assembly may further include a first and asecond source of component. The insert member of the spray assembly mayinclude three slots.

An alternate embodiment of a spray assembly for dispensing a mixture isalso provided. The spray assembly includes a connector configured foroperable engagement with a first and a second source of component and asource of pressurized fluid, and a tip operably connected to theconnector, the tip including an opening and defining a mixing chamberbetween the distal end of the elongated member and the opening of thetip, the distal end of the mixing chamber including a plurality ofradially extending slots formed about the opening, the plurality ofradially extending slots being configured to mix the first and secondcomponents prior to the combination exiting the opening in the tip. Thespray assembly may further include an elongated member extending betweenthe connector and the tip, the elongated member having at least a firstlumen configured for fluid communication with the first source ofcomponent, a second lumen configured for fluid communication with thesecond source of component, and a third lumen configured for fluidcommunication with the source of pressurized fluid,

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings, which are incorporated in and constitute apart of this specification, illustrate embodiments of the disclosureand, together with a general description of the disclosure given above,and the detailed description of the embodiment(s) given below, serve toexplain the principles of the disclosure, wherein:

FIG. 1 is an exploded perspective view of a spray assembly according tothe present disclosure;

FIG. 2 is an enlarged perspective view of the insert and applicator tipof the spray assembly of FIG. 1;

FIG. 3 is a top view of the spray assembly of FIG. 1;

FIG. 4 is a side view of the spray assembly of FIGS. 1 and 3;

FIG. 5 is a cross-sectional end view taken along line 5-5 of FIG. 3;

FIG. 6 is a cross-sectional end view taken along line 6-6 of FIG. 3;

FIG. 7 is a cross-sectional end view taken along line 7-7 of FIG. 3;

FIG. 8 is a cross-sectional end view taken along line 8-8 of FIG. 3;

FIG. 9 is a cross-sectional end view taken along line 9-9 of FIG. 3;

FIG. 10 is a cross-sectional side view of the distal end of the sprayassembly of FIGS. 1 and 3;

FIG. 11 is a distal end view of the spray assembly of FIGS. 1 and 3;

FIG. 12 is an enlarged cross-sectional side view of the distal end ofthe applicator tip of FIG. 11;

FIGS. 13A-D are side view (FIG. 13A), distal end view (FIG. 13B),proximal end view (FIG. 13C), and cross-sectional top view taken alongline 13D-13D of FIG. 13A (FIG. 13D) of the insert of FIG. 2;

FIG. 14 is an alternate embodiment of a spray assembly according to thepresent disclosure;

FIG. 15 is an enlarged cross-sectional side view of the distal end of analternate embodiment of an applicator tip according to the presentdisclosure; and

FIG. 16 is an enlarged cross-sectional end view of the applicator tip ofFIG. 14 taken along line 16-16 OF FIG. 15.

DETAILED DESCRIPTION

As shown below in FIGS. 1 and 2, an embodiment of a spray assembly,i.e., a laparoscopic spray assembly, in accordance with the presentdisclosure is shown generally as spray assembly 10. Spray assembly 10includes a Y-connector 20, an elongated body portion 30 extendingdistally from Y-connector 20, and an applicator tip 70 mounted on adistal end of elongated body portion 30. Spray assembly 10 furtherincludes an insert member 80 received between a distal end of elongatedbody portion 30 and a distal end of applicator tip 70.

Referring now to FIGS. 3 and 4, Y-connector 20 defines a substantiallyY-shaped member 21 including first and second proximal extensions 22,24, an air supply port 26, and a collar 28. Although shown in asubstantially planar arrangement, first and second proximal extensions22, 24 and air supply port 26 may be arranged in any manner. Each offirst and second proximal extensions 22, 24 includes a tab 22 a, 24 a,respectively, for operable engagement with a bayonet coupling (notshown) found on standard syringes. It is envisioned, however, that firstand second extensions 22, 24 may configured for coupling with any sourceof fluid in any manner. First and second proximal extensions 22, 24 mayfurther include component check valves 22 b, 24 b or other means forselectively regulating the flow from first and second proximalextensions 22, 24 and prevent backflow. First and second componentchannels 23, 25 extend between first and second proximal extensions 22,24 and collar 28. An air channel 27 extends between air supply port 26and collar 28. First and second component channels 23, 25 and/or airchannel 27 may be configured to include anti-backflow mechanisms. Aswill be discussed in further detail below, collar 28 maintains first andsecond component channels 23, 25 and air supply port 26 in fluidcommunication with a first and second component lumen 43, 45 and an airlumen 47 (FIG. 6), respectively, formed in inner multi-lumen shaft 40 ofelongated body portion 30.

With reference to FIGS. 5-9, elongated body portion 30 of spray assembly10 includes an inner multi-lumen shaft 40, an outer sleeve 50 (FIG. 6)surrounding inner shaft 40 and a transition member 60 extending distallyfrom outer sleeve 50 about inner shaft 40. In one embodiment, outersleeve 50 is rigid while inner multi-lumen shaft 40 and transitionmember 60 are flexible. Inner shaft 40 and outer sleeve 50 are securelyaffixed to Y-connector 20 and include a vent lumen 46 (FIG. 6)therebetween. Outer sleeve 50 includes a proximal vent or opening 52 a(FIG. 3) and a plurality of distal vents or openings 52 b (FIG. 4).Proximal and distal vents 52 a, 52 b may be of any number, size,configuration and arrangement. Distal vents 52 b are in fluidcommunication with proximal vent 52 a via vent lumen 46.

As discussed above, proximal end 40 a of inner shaft 40 engagesY-connector 20 such that first and second component lumen 43, 45 and airlumen 47 align with first and second component channels 23, 25 and airlumen 27 (FIG. 5), respectively. In one embodiment, collar 28 ofY-connector 20 is molded directly around the proximal end of elongatedbody portion 30. Alternatively, elongated body portion 30 may beselectively engagable with collar 28 such that elongated body portion 30and collar 28 may be separated and one of the two replaced. In yetanother embodiment, elongated body portion 30 may be securely affixed tocollar 28 using adhesive, sonic welding or other suitable method. Innershaft 40 may further includes a wire or other formable material 48configured to maintain elongated body portion 30 distal of outer sleeve50 in a desired straight, bent or flexed condition. A proximal end oftransition member 60 is received within vent lumen 46 between outersleeve 50 and inner shaft 40.

Transition member 60 extends from outer sleeve 50 about inner shaft 40and may be of any length. Transition member 60 may include a flexiblematerial, thereby permitting inner shaft 40 to be bent and formed. In analternate embodiment, transition member 60 may be integrally formed withinner shaft 40. In this manner, the portion of inner shaft extendingbeyond the distal end of outer sleeve 50 would have a larger diameterthan the portion of inner shaft 40 within outer sleeve 50. A distal end60 b of transition member 60 may include a groove, threading or otherconfiguration to selectively receive a applicator tip 70.

Turning now to FIGS. 8-12, applicator tip 70 is a tubular member havingan open proximal end 70 a and a substantially closed distal end 70 b.Applicator tip 70 defines an engagement portion 72, a mixing chamber 74and an outlet 76. Engagement portion 72 is configured to selectivelyengage distal end 60 b of transition member 60. Engagement portion 72may include grooves, tabs or other configurations corresponding to tabs,grooves and other configurations formed on the distal end of transitionmember 60. Engagement portion 72 may otherwise be configured to moresecurely engage the distal end of transition member 60.

Mixing chamber 74 is an annular cavity in fluid communication with firstand second component lumen 43, 45 and air lumen 47 (FIG. 5) of innershaft 40. Mixing chamber 74 includes a proximal end 74 a and outlet 76on a distal end 74 b. Mixing chamber 74 is sized to receive insert 80immediately adjacent to or flush against distal end 74 b. Outlet 76 isformed in distal end 70 b of applicator tip 70. Outlet 76 is configuredto atomize the combined first and second components. With reference toFIG. 12, in one embodiment, outlet 76, described distally from mixingchamber 74, includes a first annular portion 76 a, a first taperedportion 76 b, a second annular portion 76 c, a second tapered portion 76d and a recessed portion 76 e. Alternative configurations for atomizinga solution are known and have been envisioned for use with sprayassembly 10.

Turning now to FIGS. 13A-13D, insert 80 is defined by a substantiallyannular body 81 having proximal and distal ends 80 a, 80 b. Proximal anddistal ends 80 a, 80 b are substantial mirror images of one another.Proximal and distal ends 80 a, 80 b each define substantially annularrecesses 81 a, 81 b, respectively. In one embodiment, each of proximaland distal ends 80 a, 80 b further includes a set of slots 82 a, 82 b.Slots 82 a, 82 b are included in both proximal and distal ends 80 a, 80b in order to simplify the assembly process of spray assembly 10. It isenvisioned, however, that only one end of insert 80 may include slots82. Slots 82 a, 82 b are equally spaced about respective proximal anddistal ends 80 a, 80 b. Although shown including three slots 82 a, 82 b,an insert 80 including two or more slots has been envisioned. Each ofslots 82 a, 82 b defines an opening angling outwardly between a linetangent to recesses 81 a, 81 b, respectively, and α degreescounter-clockwise from the tangent line. In one embodiment, α is equalto twenty degrees) (20°). Slots 82 a formed on proximal end 80 a areradial offset from slots 82 b formed on distal end 80 b. Insert 80includes three spacers 84 equally spaced about and extendinglongitudinally along annular body 81. As will be discussed in furtherdetail below, spacers 84 align and maintain insert 80 within mixingchamber 74. It is envisioned that insert 80 may include more or lessthan three spacers 84.

With reference back to FIG. 10, applicator tip 70 of applicator assembly10 is shown in an assembled condition. Insert 80 is received immediatelyadjacent to, or flush against, the distal end of mixing chamber 74 ofapplicator tip 70. Spacers 84 formed on annular body 81 maintain insert80 radially centered within distal end 74 b of mixing chamber 74. Distalend 60 b of transition member 60 is received within engagement portion72 of applicator tip 70. Mixing chamber 74 is sized such that distal end60 b of transition member 60 and distal end 40 b of inner shaft 40 abutinsert 80.

In operation, first and second sources of component (not shown) areconnected with first and second proximal extensions 22, 24,respectively, formed in Y-connector 20. The first and second componentsare ejected into first and second component channels 23, 25,respectively, and travel through first and second component lumen 43,45, respectively formed in inner shaft 40. Air or other gaseous fluid isprovided to spray assembly 10 through air supply port 26. In oneembodiment, the gas supplied through air supply port 26 is a combinationof oxygen (O₂) and carbon dioxide (CO₂); however, the use of othergases, alone or in combination, is envisioned. The air flows into airchannel 27 and through air lumen 47 formed in inner shaft 47. The firstand second components and the air provided through Y-connector 20 exitfirst and second lumen 43, 45 and air lumen 47, respectively, at distalend 40 b (FIG. 3) of inner shaft 40.

The first and second components and the air exiting inner shaft 40encounter proximal end 80 a of insert 80. The components and airinitially meet as the components and air are forced around insert 80through the space created by spacers 84 between mixing chamber 74 andannular body 81. When the component/gas combination reaches distal end80 b of insert 80, the combination is further mixed by the turbulent orswirling motion created by slots 82 b as the mixture enters recess 81 b.The swirling fluid is then ejected from applicator tip 70 through outlet76 in the form of a cone spray. In the event that distal end 80 b ofinsert 80 is not flush against the distal end of chamber 74, the mixturewould not swirl through slots 82 b thereby resulting in a jet-like spraythrough outlet 76. Insert 80 is forced against and maintained flush withthe distal end of mixing chamber 74 because of the contact betweenspacers 84 on annular body 81 and mixing chamber 74. The force of thecomponents and air against insert 80 also maintains insert 80 flushagainst the distal end of applicator tip 70.

With reference to FIG. 14, in an alternate embodiment of applicator tip70, mixing chamber 74 is sized such that insert 80 is longitudinallyspaced from distal end 30 b of elongated body member 30, thereby foaminga cavity for the initial mixing of first and second components prior toencountering insert 80. In one embodiment, applicator tip 70 includes alip or ridge 72 a, to prevent engagement of elongated body portion 30with insert 80. The first and second components and gas are firstcombined within proximal end 74 a of mixing chamber 74 as the first andsecond components exit distal end 40 b of inner shaft 40. The combinedfirst and second components form a mixture that next encounters proximalend 80 a of insert 80. The mixture is forced around insert 80 throughthe space created by spacers 84 between mixing chamber 74 and annularbody 81. When the mixture reaches distal end 80 b of insert 80, themixture is further mixed and swirled by slots 82 b as the mixture entersrecess 81 b. The swirling fluid is then ejected from applicator tip 70through outlet 76 in the form of a cone spray. As discussed above, inthe event that distal end 80 b of insert 80 is not flush against distalend 74 b of chamber 74, the mixture would not swirl through slots 82 bthereby resulting in a jet-like spray. Insert 80 is maintained flushagainst distal end of mixing chamber 74 by the force of the first andsecond component and gas flowing against proximal end 80 a thereof.Insert 80 is also forced against and maintained flush with distal end ofmixing chamber 74 because of contact between spacers 84 on annular body81 and mixing chamber 74.

Turning now to FIGS. 15 and 16, distal end 74 b of mixing chamber 74 ofapplicator tip 70 may alternately be configured to include radiallyextending slots 82 c formed about opening 76. Slots 82 c are similar inform and function to slots 82 a, 82 b formed in proximal and distal ends80 a, 80 b, respectively of insert 80. As with slots 82 a, 82 bdescribed hereinabove, slots 82 c may be of any number size,configuration or orientation. In a spray assembly utilizing mixingchamber 74 having slots 82 c, insert 80 a replaces insert 80. Insert 80a is configured to be retained within mixing chamber 74 in a mannersimilar to insert 80, however, insert 80 a does not include slots 82 a,82 b. Applicator tip 70, may alternatively be configured to direct thefirst and second components into slots 82 c without insert 80 a.

Although the illustrative embodiments of the present disclosure havebeen described herein with reference to the accompanying drawings, it isto be understood that the disclosure is not limited to those preciseembodiments, and that various other changes and modifications may beeffected therein by one skilled in the art without departing from thescope or spirit of the disclosure. For example, it is envisioned thatthe spray assembly of the present disclosure may be configured to mixand dispense a mixture including more than two components. It is furtherenvisioned that the spray assembly may be configured for connection withmore than one gas supply source.

1. A spray assembly for dispensing a mixture, the assembly comprising: aconnector configured for operable engagement with a first and a secondsource of component and a source of pressurized fluid; a tip operablyconnected to the connector, the tip including an opening and defining amixing chamber between the connector and the opening of the tip; and aninsert member configured to be received in the mixing chamber, theinsert member including a plurality of radially extending slots on atleast one end of the insert, the plurality of radially extending slotsbeing configured to mix the first and second components prior to thecombination exiting the opening in the tip.
 2. The spray assembly ofclaim 1, further including an elongated member extending between theconnector and the tip, the elongated member including at least a firstlumen configured for fluid communication with the first source ofcomponent, a second lumen configured for fluid communication with thesecond source of component, and a third lumen configured for fluidcommunication with the source of pressurized fluid.
 3. The sprayassembly of claim 1, further including a first and a second source ofcomponent.
 4. The spray assembly of claim 1, wherein the insert memberincludes three slots.
 5. The spray assembly of claim 1, furtherincluding a second plurality of radially extending slots on a second endof the insert.
 6. A spray assembly for dispensing a fluid, the assemblycomprising: a connector configured for operable engagement with a firstand a second source of component and a source of pressurized fluid; anda tip located on a distal portion of the elongated member, the tipincluding an opening and defining a mixing chamber between the connectorand the opening of the tip, the distal end of the mixing chamberincluding a plurality of radially extending slots formed about theopening, the plurality of radially extending slots being configured tomix the first and second components prior to the combination exiting theopening in the tip.
 7. The spray assembly of claim 6, further includingan elongated member operably connecting the connector and the tip, theelongated member having at least a first lumen configured for fluidcommunication with the first source of component, a second lumenconfigured for fluid communication with the second source of componentand a third lumen configured for fluid communication with the source ofpressurized fluid.